Worm wheel and electric power steering apparatus

ABSTRACT

A core of a worm wheel has an axial end surface formed with a first annular recess and another axial end surface formed with a second annular recess. A rim portion has a first inner circumferential portion fixed to the first annular recess and a second inner circumferential portion fixed to the second annular recess. An outer circumferential wall surface of the second annular recess extends from a bottom surface of the second annular recess so as to be perpendicular to the bottom surface. A depth of the second annular recess is at least 0.1 mm but not deeper than half of a gate thickness.

TECHNICAL FIELD

The present invention relates to a worm wheel forming a speed reducer ofan electric power steering apparatus.

BACKGROUND ART

An electric power steering apparatus, which is mounted in vehicles, suchas automobiles, is adapted to transmit steering assistant power from anelectric motor to a steering mechanism through a speed reducer, based ona steering torque. In an electric power steering apparatus using a wormgear mechanism as the speed reducer, a worm wheel on a steering shaft isengaged with a worm on a driving shaft of the electric motor.

Such a worm wheel has a structure in which an outer circumference of acore made of metal is typically covered with a rim portion made ofsynthetic resin to reduce collision noise (rattling noise) betweenmeshed teeth due to backlash relative to the worm (see, e.g., PatentDocuments 1 to 3).

FIG. 27 illustrates a conventional example of a worm wheel. The wormwheel 100 has a core 100 made of metal and a substantially annular rimportion 201 covering an outer circumferential portion of the core 101.The core 101 is formed in a substantially circular disk shape, and has acenter hole 11 into which a shaft is fitted, and an axial end surfaceformed with a first annular recess 12. A spline 15 a is formed on theouter circumferential portion of the core 101.

The rim portion 201 is integrally formed with the core 101 by syntheticresin injection molding. A gear 21 is formed on an outer circumferentialportion of the rim portion 201. The rim portion 201 has a first innercircumferential portion 22 fixed to the first annular recess 12 of thecore 101 and a second inner circumferential portion 230 fixed to theother axial end surface of the core 101. The first inner circumferentialportion 22 extends from one axial end surface of the rim portion 201 toa radially outer region (an outer circumferential wall surface 12 a anda radially outer portion 12 b of a bottom surface) of the first annularrecess 12 and fixed to the outer circumferential wall surface 12 a andthe radially outer portion 12 b of the bottom surface.

Also, the rim portion 201 has a protrusion engaged with a valley of thespline 15 a of the core 101. By such an engagement of the protrusion ofthe rim portion 201 with the valley of the spline 15 a of the core 101,the rim portion 201 and the core 101 are coupled to each other to beintegrally rotated and thus to allow a torque to be transmittedtherebetween.

PRIOR ART DOCUMENT

Patent Document 1: JP 2004-34941 A

Patent Document 2: JP 2004-345573 A

Patent Document 3: JP 2006-22883 A

SUMMARY OF INVENTION Problem to be Solved by Invention

When an electric power steering is used in large automobiles, theassistant torque applied to an output shaft through the worm wheel isincreased. When the assistant torque is applied to the output shaftthrough the worm wheel, a moment M in a tilting direction as shown inFIG. 27 is exerted on the worm wheel from meshed portions between theworm wheel and the worm. In such a conventional worm wheel, there isroom for improvement in increasing the coupling strength between thecore bar 101 and the rim portion 201 against the moment M.

An object of the present invention is to provide a worm wheel, in whichan outer circumference of a core made of metal is covered with a rimportion made of synthetic resin, and coupling strength between the coreand the rim portion is increased as compared to a conventional product.

Means for Solving the Problem

According to an aspect of the present invention, a worm wheel includes asubstantially disk-shaped core made of metal, and a substantiallyannular rim portion made of synthetic resin and covering an outercircumferential portion of the core. A gear is formed on an outercircumferential portion of the rim portion. The rim portion isintegrally formed with the core by synthetic resin injection molding.

The core includes a center hole into which a shaft is fitted, an axialend surface formed with a first annular recess, and another axial endsurface formed with a second annular recess.

The rim portion includes a first inner circumferential portion extendingfrom an axial end surface of the rim portion to the radially outerregion of the first annular recess (the outer circumferential wallsurface of the first annular recess and the radially outer portion ofthe bottom surface thereof) and fixed to the radially outer region ofthe first annular recess, and a second inner circumferential portionextending from another axial end surface of the rim portion to aradially outer region of the second annular recess (an outercircumferential wall surface of the second annular recess and a radiallyouter portion of a bottom surface thereof) and fixed to the radiallyouter region of the second annular recess.

An outer circumferential wall surface of the second annular recessextends from a bottom surface of the second annular recess so as to beperpendicular to the bottom surface.

The rim portion is injection-molded in a state in which the core isarranged in a mold such that the second annular recess faces a gate andsuch that an axial direction of a sprue and an axial direction of thecore are aligned with each other. A depth of the second annular recessis at least 0.1 mm but not deeper than half of a gate thickness (anaxial distance between the other axial end surface of the core and theother axial end surface of the rim portion).

According to this worm wheel, the second annular recess, in addition tothe first annular recess, is formed on the core, and a fixation of thesecond inner circumference of the rim portion to the second annularrecess, in addition to a fixation of the first inner circumference ofthe rim portion to the first annular recess, is achieved, and thus thecoupling strength between the core and the rim portion is higher thanthat of a conventional worm wheel.

In addition, because the outer circumferential wall surface of thesecond annular recess extends from the bottom surface so as to beperpendicular to the bottom surface, the coupling strength between thecore and the rim portion can be further increased, as compared to a wormwheel in which the outer circumferential wall surface of the secondannular recess is not perpendicular to the side surface. Also, byemploying the above injection molding method, a flow of the resin isless disturbed during injection molding, and therefore occurrence of aweld line or the like, which is a cause of decreasing in strength of therim portion, is prevented.

A depth of the second annular recess is preferably at least 0.1 mm butnot deeper than half of a gate thickness, and more preferably set to 0.5mm or more and 3.0 mm or less.

Preferably, the other axial end surface of the core includes end surfaceportions between which, in a radial direction, the second annular recessis disposed, and each of the end surface portions is a flat surface, andpreferably, the flat surfaces forming the respective end surfaceportions are arranged on a same plane.

Preferably, the rim portion is formed by injection molding using a diskgate.

The worm wheel is suitable as a worm wheel forming a speed reducer foran electric power steering apparatus, in which a power of an electricmotor is transmitted to a steering mechanism to assist steering.

Effects of Invention

According to the worm wheel of the present invention, coupling strengthbetween the core and the rim portion is higher than that of aconventional worm wheel.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a sectional view showing a worm wheel according to a firstembodiment of the present invention.

FIG. 2 is an enlarged view showing a part of FIG. 1.

FIG. 3 is a view explaining a mold used in injection molding formanufacturing the worm wheel of the first embodiment, and a flow of asynthetic resin during injection molding.

FIG. 4 is a view explaining a method of manufacturing the worm wheel ofthe first embodiment, showing a state where the synthetic resin isfilled and solidified in the mold by injection molding.

FIG. 5 is a sectional view showing a state where the worm wheel of thefirst embodiment is attached to a speed reducer for an electric powersteering apparatus.

FIG. 6 is a view explaining a worm gear mechanism forming the speedreducer of FIG. 5.

FIG. 7 is a sectional view showing a worm wheel according to a secondembodiment of the invention.

FIG. 8 is an enlarged view showing a part of FIG. 7.

FIG. 9 is a view explaining a mold used in injection molding formanufacturing the worm wheel of the second embodiment, and a flow of asynthetic resin during injection molding.

FIG. 10 is a view explaining a method of manufacturing the worm wheel ofthe second embodiment, showing a state where the synthetic resin isfilled and solidified in the mold by injection molding.

FIG. 11 is a sectional view showing a state where the worm wheel of thesecond embodiment is attached to a speed reducer for an electric powersteering apparatus.

FIG. 12 is a view explaining a worm gear mechanism forming the speedreducer of FIG. 11.

FIG. 13 is a sectional view showing a worm wheel according to a thirdembodiment of the invention.

FIG. 14 is an enlarged view showing a part of FIG. 13.

FIG. 15 is a sectional view showing a worm wheel according to a fourthembodiment of the invention.

FIG. 16 is an enlarged view showing a part of FIG. 15.

FIG. 17 is a view explaining a mold used in injection molding formanufacturing the worm wheel of the fourth embodiment, and a flow of asynthetic resin during injection molding.

FIG. 18 is a view explaining a method of manufacturing the worm wheel ofthe fourth embodiment, showing a state where the synthetic resin isfilled and solidified in the mold by injection molding.

FIG. 19 is a sectional view showing a state where the worm wheel of thefourth embodiment is attached to a speed reducer for an electric powersteering apparatus.

FIG. 20 is a view explaining a worm gear mechanism forming the speedreducer of FIG. 19.

FIG. 21 is a sectional view showing a worm wheel according to a fifthembodiment of the invention.

FIG. 22 is an enlarged view showing a part of FIG. 21.

FIG. 23 is a view explaining a mold used in injection molding formanufacturing the worm wheel of the fifth embodiment, and a flow of asynthetic resin during injection molding.

FIG. 24 is a view explaining a method of manufacturing the worm wheel ofthe fifth embodiment, showing a state where the synthetic resin isfilled and solidified in the mold by injection molding.

FIG. 25 is a sectional view showing a state where the worm wheel of thefifth embodiment is attached to a speed reducer for an electric powersteering apparatus.

FIG. 26 is a view explaining a worm gear mechanism forming the speedreducer of FIG. 25.

FIG. 27 is a sectional view showing a worm wheel according to theconventional example.

EMBODIMENTS OF INVENTION

Embodiments of the present invention will be now described, but theinvention is not limited to the following embodiments.

Now, a first embodiment of the present invention will be described. FIG.1 is a sectional view showing a worm wheel according to the firstembodiment, and FIG. 2 is an enlarged view showing a part thereof.

As shown in FIGS. 1 and 2, the worm wheel 10 of the first embodiment hasa core 1 made of metal and a substantially annular rim portion 2covering an outer circumference 15 of the core 1. The core 1 is arrangedon the substantially center of the rim portion 2, as viewed in an axialdirection thereof.

The core 1 is formed in a substantially circular disk shape. The core 1has a center hole 11, into which a shaft is fitted, one axial endsurface having a first annular recess 12 formed thereon, the other axialend surface having a second annular recess 13 formed thereon, and theouter circumference 15 having a spline 15 a formed thereon. As viewed inan axial direction, the spline 15 a is provided on a part of the outercircumference 15, on the side of which the second annular recess 13 isformed. The other part of the outer circumference 15, on the side ofwhich the first annular recess 12 is formed, is configured as acylindrical surface. A part of the core 1, which is located moreradially inward than the first annular recess 12, becomes a boss portion11 a having the center hole 11.

As shown in FIG. 2, the other axial end surface of the core 1 has endsurface portions 13 a, 13 b, between which the second annular recess 13is located as viewed in a radial direction thereof. The end surfaceportion 13 a, 13 b are a flat surface and are arranged on the same planeas shown by a one-dot chain line F. The second annular recess 13 has abottom surface 13 d, an outer circumferential wall surface 13 cextending in the axial direction from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, and an inner circumferentialwall surface 13 e extending from the bottom surface 13 d toward the endsurface portion 13 b in a tapered shape to form an obtuse angle relativeto the bottom surface 13 d. The outer circumferential wall surface 13 cof the second annular recess 13 is configured as a cylindrical surface.An outer circumferential wall surface 12 a of the first annular recess12 is configured as a cylindrical surface having a diameter smaller thanthat of the outer circumferential wall surface 13 c of the secondannular recess 13. Namely, the outer circumferential wall surface 13 cof the second annular recess 13 is provided more radially outward thanthe outer circumferential wall surface 12 a of the first annular recess12.

The rim portion 2 is integrally formed with the core 1 by injectionmolding of synthetic resin. A gear 21 is formed on an outercircumferential portion of the rim portion 2. The rim portion 2 has afirst inner circumferential portion 22 fixed to the first annular recess12 of the core 1 and a second inner circumferential portion 23 fixed tothe second annular recess 13.

As shown in FIG. 2, the first inner circumferential portion 22 extendsfrom one axial end surface of the rim portion 2 to a radially outerregion of the first annular recess 12 and is fixed to the outercircumferential wall surface 12 a of the first annular recess 12 and aradially outer portion 12 b of a bottom surface of the first annularrecess 12. An inner circumferential surface of the first innercircumferential portion 12 has a cylindrical surface abutted against theradially outer portion 12 b of the bottom surface of the first annularrecess 12 and an inclined surface extending radially outward from thecylindrical surface toward the one axial end surface of the rim portion2. The second inner circumferential portion 23 extends from the otheraxial end surface of the rim portion 2 to a radially outer region of thesecond annular recess 13 and is fixed to the outer circumferential wallsurface 13 c of the second annular recess 13 and a radially outerportion of the bottom surface 13 d of the second annular recess 13. Aninner circumferential surface of the second inner circumferentialportion 23 is configured as an inclined surface extending radiallyoutward from the bottom surface 13 d of the second annular recess 13toward the other axial end surface of the rim portion 2 (see a line L inFIG. 4). A radial position, at which the inner circumferential surfaceof the first inner circumferential portion 22 is abutted against theradially outer portion 12 b of the bottom surface of the first annularrecess 12, is approximately equal to a radial position, at which theinner circumferential surface of the second inner circumferentialportion 23 is abutted against the bottom surface 13 d of the secondannular recess 13.

The rim portion 2 has a protrusion engaged with a valley of the spline15 a of the core 1. By such an engagement of the protrusion of the rimportion 2 with the valley of the spline 15 a of the core 1, the rimportion 2 and the core 1 are coupled to each other to be integrallyrotated and thus to allow a torque to be transmitted therebetween.

The worm wheel 10 is manufactured according to the following method.

As shown in FIG. 3, a mold 3 used in injection molding has a firstmember 31, a second member 32, a third member 33, and a fourth member34. The first member 31 has a protrusion 31 a adapted to be fitted inthe center hole 11 of the core 1. The second member 32 has a protrusion32 a adapted to be fitted in the first annular recess 12 and a recessedportion 32 b forming a cavity. The third member 33 has a recessedportion 33 a forming the cavity and a parting surface 33 b. The fourthmember 34 a has a sprue 34 a, a recessed portion 34 b forming a diskgate, and a parting surface 34 c.

First, the core 1, which is made of metal, is manufactured by aconventionally known method. At this time, a depth D of the secondannular recess 12 is in a range of 0.5 mm to half of a gate thickness T.In addition, even when the gate thickness T is 6.0 mm or more, the depthD of the second annular recess 12 is set to 3.0 mm or less.

Then, the core 1 is arranged in the mold 3 such that the second annularrecess 13 faces the gate and such that an axial direction of the sprue34 a and the axial direction of the core 1 are aligned with each other.At this time, an inclined inner circumferential surface of the recessedportion 34 b forming the disk gate faces the inner circumferential wallsurface 13 e of the second annular recess 13 of the core 1 (they are atsubstantially the same radial position, and is parallel to the innercircumferential wall surface 13 e of the second annular recess 13 of thecore 1. Then, by operating an injection molding machine, the rim portion2 is integrally molded with the core 1.

At this time, a synthetic resin, which is supplied from a nozzle of theinjection molding machine, is introduced from the sprue 34 a into thecavity through the disk gate. As shown by a line 4 a in FIG. 3, thesynthetic resin goes around from the other axial end surface (surfacehaving the second annular recess 13 formed thereon) of the core 1 intothe one axial end surface thereof (surface having the first annularrecess 12 formed thereon) through the outside of the outer circumference15.

FIG. 4 shows a state where the synthetic resin 4 is filled in the moldby injection molding and then the synthetic resin 4 is solidified. Afterthe mold 3 is removed in such a state, the synthetic resin 4 isseparated in a cone shape along a line L, thereby obtaining the wormwheel 10 shown FIG. 1. A line 21 a in FIG. 4 is a line representing avalley of the gear 21.

In the first embodiment, a relationship of the depth D of the secondannular recess 13 of the core 1 and the gate thickness T satisfies D≦T/2(namely, the depth D of the second annular recess 13 of the core 1 isnot deeper than half of an axial distance between the other axial endsurface of the core 1 and the end surface portion 13 a (the other axialend surface) of the rim portion 2), and the end surface portions 13 a,13 b, between which the second annular recess 13 is disposed, arearranged on the same plane F. Therefore, a flow of the synthetic resinis hardly disturbed during injection molding of the synthetic resin.Namely, in the case where the depth D of the second annular recess 13 isas small as possible, swirling is hardly occurred when the syntheticresin flows. Also, if the end surface portions 13 a, 13 b between whichthe second annular recess 13 is disposed are not arranged on the sameplane, swirling is easily occurred when the synthetic resin flows,thereby reducing strength of the synthetic resin. However, according tothe present embodiment, because the end surface portions 13 a, 13 bbetween which the second annular recess 13 is disposed are arranged onthe same plane F, the synthetic resin can be smoothly flowed. Therefore,the synthetic resin is clearly expanded over the whole of the cavity (upto the first annular recess 12, which is a terminal part of the flow),thereby preventing occurrence of a weld line or the like which is acause of decreasing in coupling strength between the core 1 and the rimportion 2.

The worm wheel 10 includes the second annular recess 13 as well as thefirst annular recess 12 formed on the core 1, and has a fixation of thesecond inner circumferential portion 23 of the rim portion 2 to thesecond annular recess 12, in addition to a fixation of the first innercircumferential portion 22 of the rim portion 2 to the first annularrecess 12. Thus, coupling strength between the core 1 and the rimportion 2 is higher than that of a worm wheel 100 in FIG. 27. Also,because the outer circumferential wall surface 13 c of the secondannular recess 13 extends from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, the worm wheel 10 can be madeto have a further increased coupling strength between the core 1 and therim portion 2, as compared to a configuration in which the wall surface13 c is a tapered surface.

In addition, although the worm wheel 10 according to the firstembodiment is provided with only one second annular recess 13 on theaxial end surface of the core 1, when the depth D of the second annularrecess 12 cannot be set to be 0.5 mm or more, a plurality of secondannular recesses 12, which have a depth D of 0.1 mm or more and 0.4 mmor less, may be provided on the axial end surface of the core 1, therebyincreasing in coupling strength between the core 1 and the rim portion2. To ensure coupling strength between the core 1 and the rim portion 2,a lower threshold of D is set to 0.1 mm.

The worm wheel 10 is used in a speed reducer for a worm gear mechanismof an electric power steering apparatus.

FIG. 5 shows the electric power steering apparatus having the speedreducer, into which the worm wheel 10 is incorporated. FIG. 6 is a viewexplaining the speed reducer worm gear mechanism in FIG. 5.

In this example, an output shaft 51 and a steering shaft 52 in asteering mechanism for the electric power steering apparatus are coupledto each other by a torsion bar 53. A torque sensor 55 is installed on aninner surface of a housing 54 rotatably supporting the output shaft 51.The torque sensor 55 measures a torque transmitted between the steeringshaft 52 and the output shaft 51.

As shown in FIG. 6, a worm 58 is coupled on an output shaft 57 of anelectric motor 56. The gear 21 of the worm wheel 10 is engaged with theworm 58.

According to the electric power steering apparatus, an electric currentis supplied to the electric motor 56 based on a torque value measured bythe torque sensor 55, and thus an appropriate assistant torque isapplied to the output shaft 51 through the speed reducer including theworm 57 and the worm wheel 10.

Next, a second embodiment of the present invention will be described.FIG. 7 is a sectional view showing a worm wheel according to the secondembodiment, and FIG. 8 is an enlarged view showing a part thereof.

As shown in FIGS. 7 and 8, the worm wheel 10A of the second embodimenthas a core 1A made of metal and a substantially annular rim portion 2Acovering an outer circumference 15 of the core 1A. The core 1A isarranged on the substantially center of the rim portion 2A, as viewed inan axial direction thereof.

The core 1A is formed in a substantially circular disk shape. The core1A has a center hole 11, into which a shaft is fitted, one axial endsurface having a first annular recess 12 formed thereon, the other axialend surface having a second annular recess 13 formed thereon, a thirdannular recess 14 formed on an outer circumferential wall surface(surface located in a radially outer region) 12 a of the first annularrecess 12, and a spline 15 a formed on the outer circumference 15. Asviewed in an axial direction, the spline 15 a is provided on a part ofthe outer circumference 15, on the side of which the second annularrecess 13 is formed. The other part of the outer circumference 15, onthe side of which the first annular recess 12 is formed, is configuredas a cylindrical surface. A part of the core 1A, which is located moreradially inward than the first annular recess 12, becomes a boss portion11 a having the center hole 11.

As shown in FIG. 8, the other axial end surface of the core 1A has endsurface portions 13 a, 13 b, between which the second annular recess 13is located as viewed in a radial direction thereof. The end surfaceportions 13 a, 13 b are flat surfaces and are arranged on the same planeas shown by a one-dot chain line F. The second annular recess 13 has abottom surface 13 d, an outer circumferential wall surface 13 cextending in the axial direction from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, and an inner circumferentialwall surface 13 e extending from the bottom surface 13 d toward the endsurface portion 13 b in a tapered shape to form an obtuse angle relativeto the bottom surface 13 d. The outer circumferential wall surface 13 cof the second annular recess 13 is configured as a cylindrical surface.A part of the outer circumferential wall surface 12 a of the firstannular recess 12 except the third annular recess 14 is configured as acylindrical surface having a diameter smaller than that of the outercircumferential wall surface 13 c of the second annular recess 13.Namely, the outer circumferential wall surface 13 c of the secondannular recess 13 is provided more radially outward than the part of theouter circumferential wall surface 12 a of the first annular recess 12except the third annular recess 14.

The third annular recess 14, as shown in FIG. 8, has a radial surface 14a extending in a direction approximately equal to a radial direction ofthe core 1A and a tapered surface 14 b configured to be expanded on anopening side of the third annular recess 14.

The rim portion 2A is integrally formed with the core 1A by injectionmolding of synthetic resin. A gear 21 is formed on an outercircumferential portion of the rim portion 2A. The rim portion 2A has afirst inner circumferential portion 22 fixed to the first annular recess12 of the core 1A, a second inner circumferential portion 23 fixed tothe second annular recess 13, and a protrusion 24 engaged with the thirdannular recess 14.

As shown in FIG. 8, the first inner circumferential portion 22 extendsfrom one axial end surface of the rim portion 2A to a radially outerregion of the first annular recess 12 and is fixed to the outercircumferential wall surface 12 a of the first annular recess 12 and aradially outer portion 12 b of a bottom surface of the first annularrecess 12. An inner circumferential surface of the first innercircumferential portion 12 has a cylindrical surface abutted against theradially outer portion 12 b of the bottom surface of the first annularrecess 12 and an inclined surface extending radially outward from thecylindrical surface toward the one axial end surface of the rim portion2A. The second inner circumferential portion 23 extends from the otheraxial end surface of the rim portion 2A to a radially outer region ofthe second annular recess 13 and is fixed to the outer circumferentialwall surface 13 c of the second annular recess 13 and a radially outerportion of the bottom surface 13 d of the second annular recess 13. Aninner circumferential surface of the second inner circumferentialportion 23 is configured as an inclined surface extending radiallyoutward from the bottom surface 13 d of the second annular recess 13toward the other axial end surface of the rim portion 2A (see a line Lin FIG. 10). A radial position, at which the inner circumferentialsurface of the first inner circumferential portion 22 is abutted againstthe radially outer portion 12 b of the bottom surface of the firstannular recess 12, is approximately equal to a radial position, at whichthe inner circumferential surface of the second inner circumferentialportion 23 is abutted against the bottom surface 13 d of the secondannular recess 13.

The rim portion 2A has a protrusion engaged with a valley of the spline15 a of the core 1A. By such an engagement of the protrusion of the rimportion 2A with the valley of the spline 15 a of the core 1A, the rimportion 2A and the core 1A are coupled to each other to be integrallyrotated and thus to allow a torque to be transmitted therebetween.

The worm wheel 10A is manufactured according to the following method.

As shown in FIG. 9, a mold 3 used in injection molding has a firstmember 31, a second member 32, a third member 33, and a fourth member34. The first member 31 has a protrusion 31 a adapted to be fitted inthe center hole 11 of the core 1A. The second member 32 has a protrusion32 a adapted to be fitted in the first annular recess 12 and a recessedportion 32 b forming a cavity. The third member 33 has a recessedportion 33 a forming the cavity and a parting surface 33 b. The fourthmember 34 a has a sprue 34 a, a recessed portion 34 b forming a diskgate, and a parting surface 34 c.

First, the core 1, which is made of metal, is manufactured by aconventionally known method. At this time, a depth D of the secondannular recess 12 is in a range of 0.5 mm to half of a gate thickness T.In addition, even when the gate thickness T is 6.0 mm or more, the depthD of the second annular recess 12 is set to 3.0 mm or less.

Then, the core 1A is arranged in the mold 3 such that the second annularrecess 13 faces the gate and such that an axial direction of the sprue34 a and the axial direction of the core 1A are aligned with each other.At this time, an inclined inner circumferential surface of the recessedportion 34 b forming the disk gate is a parallel to the innercircumferential wall surface 13 e of the second annular recess 13 of thecore 1A. Then, by operating an injection molding machine, the rimportion 2A is integrally molded with the core 1A.

At this time, a synthetic resin, which is supplied from a nozzle of theinjection molding machine, is introduced from the sprue 34 a into thecavity through the disk gate. As shown by a line 4 a in FIG. 9, thesynthetic resin goes around from the other axial end surface (surfacehaving the second annular recess 13 formed thereon) of the core 1A intothe one axial end surface thereof (surface having the first annularrecess 12 formed thereon) through the outside of the outer circumference15, and then reaches the third annular recess 14.

FIG. 10 shows a state where the synthetic resin 4 is filled in the moldby injection molding and then the synthetic resin 4 is solidified. Afterthe mold 3 is removed in such a state, the synthetic resin 4 isseparated in a cone shape along a line L, thereby obtaining the wormwheel 10A shown FIG. 7. A line 21 a in FIG. 10 is a line representing avalley of the gear 21.

In the second embodiment, a relationship of the depth D of the secondannular recess 13 of the core 1A and the gate thickness T satisfiesD≦T/2 (namely, the depth D of the second annular recess 13 of the core1A is not deeper than half of an axial distance between the other axialend surface of the core 1A and the end surface portion 13 a (the otheraxial end surface) of the rim portion 2A), the end surface portions 13a, 13 b, between which the second annular recess 13 is disposed, arearranged on the same plane F, and the third annular recess 14 has thetapered surface 14 b. Therefore, a flow of the synthetic resin is hardlydisturbed during injection molding of the synthetic resin. Thus, thesynthetic resin is clearly expanded over the whole of the cavity (up tothe third annular recess 14, which is a terminal part of the flow),thereby preventing occurrence of a weld line or the like which is acause of decreasing in coupling strength between the core 1A and the rimportion 2A.

The worm wheel 10A includes the second annular recess 13 and the thirdannular recess 14 as well as the first annular recess 12 formed on thecore 1A, and has a fixation of the second inner circumferential portion23 of the rim portion 2A to the second annular recess 12 and anengagement of the protrusion 24 of the rim portion 2A with the thirdannular recess 14, in addition to a fixation of the first innercircumferential portion 22 of the rim portion 2A to the first annularrecess 12. Thus, coupling strength between the core 1A and the rimportion 2A is higher than that of a worm wheel 100 in FIG. 27. Also,because the outer circumferential wall surface 13 c of the secondannular recess 13 extends from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, the worm wheel 10A can be madeto have a further increased coupling strength between the core 1A andthe rim portion 2A, as compared to a configuration in which the wallsurface 13 c is a tapered surface.

Although the worm wheel 10A according to the second embodiment isprovided with only one second annular recess 13 on the axial end surfaceof the core 1A, when the depth D of the second annular recess 12 cannotbe set to be 0.5 mm or more, a plurality of second annular recesses 12,which have a depth D of 0.1 mm or more and 0.4 mm or less, may beprovided on the axial end surface of the core 1A, thereby increasing incoupling strength between the core 1A and the rim portion 2A.

The worm wheel 10A is used in a speed reducer for a worm gear mechanismforming an electric power steering apparatus.

FIG. 11 shows the electric power steering apparatus having the speedreducer, into which the worm wheel 10A is incorporated. FIG. 12 is aview explaining the speed reducer worm gear mechanism in FIG. 11.

In this example, an output shaft 51 and a steering shaft 52 in asteering mechanism for the electric power steering apparatus are coupledto each other by a torsion bar 53. A torque sensor 55 is installed on aninner surface of a housing 54 rotatably supporting the output shaft 51.The torque sensor 55 measures a torque transmitted between the steeringshaft 52 and the output shaft 51.

As shown in FIG. 12, a worm 58 is coupled on an output shaft 57 of anelectric motor 56. The gear 21 of the worm wheel 10A is engaged with theworm 58.

According to the electric power steering apparatus, an electric currentis supplied to the electric motor 56 based on a torque value measured bythe torque sensor 55, and thus an appropriate assistant torque isapplied to the output shaft 51 through the speed reducer including theworm 57 and the worm wheel 10A.

Next, a third embodiment of the present invention will be described.FIG. 13 is a sectional view showing a worm wheel according to the thirdembodiment, and FIG. 14 is an enlarged view showing a part thereof.

As shown in FIGS. 13 and 8, the worm wheel 10B of the third embodimenthas a core 1B made of metal and a substantially annular rim portion 2Bcovering an outer circumference 15 of the core 1B. The core 1B isarranged on the substantially center of the rim portion 2B, as viewed inan axial direction thereof.

The core 1B is formed in a substantially circular disk shape. The core1B has a center hole 11, into which a shaft is fitted, one axial endsurface having a first annular recess 12 formed thereon, the other axialend surface having a second annular recess 13 formed thereon, a thirdannular recess 14A formed on a radially outer portion (surface locatedin a radially outer region) 12 b of a bottom surface of the firstannular recess 12, and the outer circumference 15 having a spline 15 aformed thereon. As viewed in an axial direction, the spline 15 a isprovided on a part of the outer circumference 15, on the side of whichthe second annular recess 13 is formed. The other part of the outercircumference 15, on the side of which the first annular recess 12 isformed, is configured as a cylindrical surface. A part of the core 1B,which is located more radially inward than the first annular recess 12,becomes a boss portion 11 a having the center hole 11.

As shown in FIG. 14, the other axial end surface of the core 1B has endsurface portions 13 a, 13 b, between which the second annular recess 13is located as viewed in a radial direction thereof. The end surfaceportions 13 a, 13 b are flat surfaces and are arranged on the same planeas shown by a one-dot chain line F. The second annular recess 13 has abottom surface 13 d, an outer circumferential wall surface 13 cextending in the axial direction from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, and an inner circumferentialwall surface 13 e extending from the bottom surface 13 d toward the endsurface portion 13 b in a tapered shape to form an obtuse angle relativeto the bottom surface 13 d. The outer circumferential wall surface 13 cof the second annular recess 13 is configured as a cylindrical surface.An outer circumferential wall surface 12 a of the first annular recess12 is configured as a cylindrical surface having a diameter smaller thanthat of the outer circumferential wall surface 13 c of the secondannular recess 13. Namely, the outer circumferential wall surface 13 cof the second annular recess 13 is provided more radially outward thanthe outer circumferential wall surface 12 a of the first annular recess12.

The third annular recess 14A, as shown in FIG. 14, has an axial surface14 c extending in a direction approximately equal to the axial directionof the core 1B and a tapered surface 14 d configured to be expanded onan opening side of the third annular recess 14A.

The rim portion 2B is integrally formed with the core 1B by injectionmolding of synthetic resin. A gear 21 is formed on an outercircumferential portion of the rim portion 2B. The rim portion 2B has afirst inner circumferential portion 22 fixed to the first annular recess12 of the core 1B, a second inner circumferential portion 23 fixed tothe second annular recess 13, and a protrusion 24A engaged with thethird annular recess 14A.

As shown in FIG. 14, the first inner circumferential portion 22 extendsfrom one axial end surface of the rim portion 2B to a radially outerregion of the first annular recess 12 and is fixed to the outercircumferential wall surface 12 a of the first annular recess 12 and theradially outer portion 12 b of the bottom surface thereof. An innercircumferential surface of the first inner circumferential portion 12has a cylindrical surface abutted against the radially outer portion 12b of the bottom surface of the first annular recess 12 and an inclinedsurface extending radially outward from the cylindrical surface towardthe one axial end surface of the rim portion 2B. The second innercircumferential portion 23 extends from the other axial end surface ofthe rim portion 2B to a radially outer region of the second annularrecess 13 and is fixed to the outer circumferential wall surface 13 c ofthe second annular recess 13 and a radially outer portion of the bottomsurface 13 d thereof. An inner circumferential surface of the secondinner circumferential portion 23 is configured as an inclined surfaceextending radially outward from the bottom surface 13 d of the secondannular recess 13 toward the other axial end surface of the rim portion2B. A radial position, at which the inner circumferential surface of thefirst inner circumferential portion 22 is abutted against the radiallyouter portion 12 b of the bottom surface of the first annular recess 12,is approximately equal to a radial position, at which the innercircumferential surface of the second inner circumferential portion 23is abutted against the bottom surface 13 d of the second annular recess13.

The rim portion 2B has a protrusion engaged with a valley of the spline15 a of the core 1B. By such an engagement of the protrusion of the rimportion 2B with the valley of the spline 15 a of the core 1B, the rimportion 2B and the core 1B are coupled to each other to be integrallyrotated and thus to allow a torque to be transmitted therebetween.

The worm wheel 10B is manufactured by the same method as those of theworm wheel 10A according to the second embodiment, except that a shapeof the core used is different therefrom.

In the third embodiment, a relationship of the depth D of the secondannular recess 13 and the gate thickness T satisfies D≦T/2, the endsurface portions 13 a, 13 b, between which the second annular recess 13is disposed, are arranged on the same plane F, and the third annularrecess 14A has the tapered surface 14 d. Therefore, a flow of thesynthetic resin is hardly disturbed during injection molding of thesynthetic resin. Thus, the synthetic resin is clearly expanded over thewhole of the cavity (up to the third annular recess 14A, which is aterminal part of the flow), thereby preventing occurrence of a weld lineor the like which is a cause of decreasing in coupling strength betweenthe core 1A and the rim portion 2B.

The worm wheel 10B includes the second annular recess 13 and the thirdannular recess 14A as well as the first annular recess 12 formed on thecore 1B, and has a fixation of the second inner circumferential portion23 of the rim portion 2B to the second annular recess 12 and anengagement of the protrusion 24A of the rim portion 2B with the thirdannular recess 14A, in addition to a fixation of the first innercircumferential portion 22 of the rim portion 2B to the first annularrecess 12. Thus, coupling strength between the core 1B and the rimportion 2B is higher than that of a worm wheel 100 in FIG. 27.

Also, because the outer circumferential wall surface 13 c of the secondannular recess 13 extends from the bottom surface 13 d to beperpendicular to the bottom surface 13 d, the worm wheel 10B can be madeto have a further increased coupling strength between the core 1B andthe rim portion 2B, as compared to a configuration in which the wallsurface 13 c is a tapered surface.

The worm wheel 10B is identical to the worm wheel 10A according to thesecond embodiment, except that a position, at which the third annularrecess is formed, is different therefrom, but due such a difference, theworm wheel 10B has advantages over the worm wheel 10A in the followingrespects.

The third annular recess 14 of the worm wheel 10A is adapted to berecessed in a radial direction of the core 1A, whereas the third annularrecess 14A of the worm wheel 10B is adapted to be recessed in an axialdirection of the core 1B. When a core of a shape not having the thirdannular recess 14 or 14A is formed by plastic working, such as forging,forming is performed by applying a forming load in an axial direction ofthe core. Therefore, in the case of the core 1B having the third annularrecess 14A, the third annular recess 14A is simultaneously formed by aforming load applied in the axial direction of the core 1B, whereas inthe case of the core 1A having the third annular recess 14, formingperformed by applying a forming load in a direction perpendicular to theaxial direction of the core 1A is additionally required to form thethird annular recess 14. Thus, as compared to the worm wheel 10A, theworm wheel 10B can reduce cost incurred in forming of the core.

FIG. 15 is a sectional view showing a worm wheel according to a fourthembodiment, and FIG. 16 is an enlarged view showing a part thereof.

As shown in FIGS. 15 and 16, the worm wheel 10C of this embodiment has acore 1C made of metal and a substantially annular rim portion 2Ccovering an outer circumference 15 of the core 1C.

The core 1C is formed in a substantially circular disk shape. The core1C has a center hole 11, into which a shaft is fitted, one axial endsurface having a first annular recess 12 formed thereon, the other axialend surface having a second annular recess 13A formed thereon, and theouter circumference 15 having a spline 15 a formed thereon. As viewed inan axial direction, the spline 15 a is provided on a part of the outercircumference 15, on the side of which the second annular recess 13A isformed. The other part of the outer circumference 15, on the side ofwhich the first annular recess 12 is formed, is configured as acylindrical surface. A part of the core 1C, which is located moreradially inward than the first annular recess 12, becomes a boss portion11 a having the center hole 11.

As shown in FIG. 16, the other axial end surface of the core 1C has endsurface portions 13Aa, 13Ab, between which the second annular recess 13Ais located as viewed in a radial direction thereof. The end surfaceportion 13Aa, 13Ab are a flat surface and are arranged on the same planeas shown by a one-dot chain line F. The second annular recess 13A has abottom surface 13Ad, and an inner circumferential wall surface 13Aeextending from the bottom surface 13Ad toward the end surface portion13Ab in a tapered shape to form an obtuse angle relative to the bottomsurface 13Ad.

An outer circumferential wall surface of the second annular recess 13Ahas a tapered surface 13Ac extending from the bottom surface 13Ad towardthe end surface portion 13Aa to form an obtuse angle relative to thebottom surface 13Ad, a third annular recess 14A formed radially outsidethe tapered surface 13Ac, and an outer tapered surface 13Af formedradially outside the third annular recess 14A. A cross-sectional shapeof the third annular recess 14A is a right-angled triangle having, astwo sides, a surface (surface along a line L1) parallel to the bottomsurface 13Ad of the second annular recess 13A and a surface (surfacealong a line L2) perpendicular to the bottom surface 13Ad. The taperedsurface 13Ac and the outer tapered surface 13Af are arranged on the sameline L3. Namely, the outer tapered surface 13Af is configured as a partof a surface extending from the tapered surface 13Ac. The surface(surface along the line L2) of the third annular recess 14Aperpendicular to the bottom surface 13Ad of the second annular recess13A is configured as a cylindrical surface. An outer circumferentialwall surface 12 a of the first annular recess 12 is configured as acylindrical surface having a diameter approximately equal to that of thesurface of the third annular recess 14A perpendicular to the bottomsurface 13Ad of the second annular recess 13A.

The rim portion 2C is integrally formed with the core 1C by injectionmolding of synthetic resin. A gear 21 is formed on an outercircumferential portion of the rim portion 2C. The rim portion 2C has afirst inner circumferential portion 22 fixed to the first annular recess12 of the core 1C and a second inner circumferential portion 23A fixedto the second annular recess 13A.

As shown in FIG. 16, the first inner circumferential portion 22 extendsfrom one axial end surface of the rim portion 2C to a radially outerregion of the first annular recess 12 and is fixed to the outercircumferential wall surface 12 a of the first annular recess 12 and aradially outer portion 12 b of a bottom surface of the first annularrecess 12. An inner circumferential surface of the first innercircumferential portion 12 has a cylindrical surface abutted against theradially outer portion 12 b of the bottom surface of the first annularrecess 12 and an inclined surface extending radially outward from thecylindrical surface toward the one axial end surface of the rim portion2C. The second inner circumferential portion 23A extends from the otheraxial end surface of the rim portion 2C to a radially outer region ofthe second annular recess 13A and is fixed to the outer circumferentialwall surface (tapered surface 13Ac, third annular recess 14A, and outertapered surface 13Af) of the second annular recess 13A and a radiallyouter portion of the bottom surface 13Ad thereof. An innercircumferential surface of the second inner circumferential portion 23Ais configured as an inclined surface extending radially outward from thebottom surface 13Ad of the second annular recess 13A toward the otheraxial end surface of the rim portion 2C (see a line L in FIG. 18). Theinner circumferential surface of the second inner circumferentialportion 23A extends along the line L3 to be parallel to the taperedsurface 13Ac and the outer tapered surface 13Af of the second annularrecess 13A, and thus a thickness of the second inner circumferentialportion 23A in a range between the bottom surface 13Ad of the secondannular recess 13A and the end surface portion 13Aa is adapted to beapproximately constant, except a part thereof inside the third annularrecess 14A. A radial position, at which the inner circumferentialsurface of the second inner circumferential portion 23A and the firstinner circumferential portion 22 is abutted against the radially outerportion 12 b of the bottom surface of the first annular recess 12, isapproximately equal to a radial position, at which the innercircumferential surface of the second inner circumferential portion 23Ais abutted against the bottom surface 13Ad of the second annular recess13A.

The rim portion 2C has a protrusion engaged with a valley of the spline15 a of the core 1C. By such an engagement of the protrusion of the rimportion 2C with the valley of the spline 15 a of the core 1C, the rimportion 2C and the core 1C are coupled to each other to be integrallyrotated and thus to allow a torque to be transmitted therebetween.

The worm wheel 10C is manufactured according to the following method.

As shown in FIG. 17, a mold 3 used in injection molding has a firstmember 31, a second member 32, a third member 33, and a fourth member34. The first member 31 has a protrusion 31 a adapted to be fitted inthe center hole 11 of the core 1C. The second member 32 has a protrusion32 a adapted to be fitted in the first annular recess 12 and a recessedportion 32 b forming a cavity. The third member 33 has a recessedportion 33 a forming the cavity and a parting surface 33 b. The fourthmember 34 a has a sprue 34 a, a recessed portion 34 b forming a diskgate, and a parting surface 34 c.

First, the core 1C, which is made of metal, is manufactured by aconventionally known method. At this time, a depth D of the secondannular recess 12 is in a range of 0.5 mm to half of a gate thickness T.In addition, even when the gate thickness T is 6.0 mm or more, the depthD of the second annular recess 12 is set to 3.0 mm or less.

Then, the core 1C is arranged in the mold 3 such that the second annularrecess 13A faces the gate and such that an axial direction of the sprue34 a and the axial direction of the core 1C are aligned with each other.At this time, an inclined inner circumferential surface of the recessedportion 34 b forming the disk gate faces the inner circumferential wallsurface 13Ae of the second annular recess 13A of the core 1C (they areat substantially the same radial position), and is parallel to the innercircumferential wall surface 13Ae of the second annular recess 13A ofthe core 1C. Then, by operating an injection molding machine, the rimportion 2C is integrally molded with the core 1C.

At this time, a synthetic resin, which is supplied from a nozzle of theinjection molding machine, is introduced from the sprue 34 a into thecavity through the disk gate. As shown by a line 4 a in FIG. 17, thesynthetic resin goes around from the other axial end surface (surfacehaving the second annular recess 13A formed thereon) of the core 1C intothe one axial end surface thereof (surface having the first annularrecess 12 formed thereon) through the outside of the outer circumference15.

FIG. 18 shows a state where the synthetic resin 4 is filled in the moldby injection molding and then the synthetic resin 4 is solidified. Afterthe mold 3 is removed in such a state, the synthetic resin 4 isseparated in a cone shape along a line L, thereby obtaining the wormwheel 10C shown FIG. 15. A line 21 a in FIG. 18 is a line representing avalley of the gear 21.

In the fourth embodiment, a relationship of the depth D of the secondannular recess 13A of the core 1C and the gate thickness T satisfiesD≦T/2, the tapered surfaces (tapered surface 13Ac and outer taperedsurface 13Af) are formed radially inward and outward of the thirdannular recess 14A, and the end surface portions 13Aa, 13Ab, betweenwhich the second annular recess 13A is disposed, are arranged on thesame plane F. Therefore, a flow of the synthetic resin is hardlydisturbed during injection molding of the synthetic resin. Thus, thesynthetic resin is clearly expanded over the whole of the cavity (up tothe first annular recess 12, which is a terminal part of the flow),thereby preventing occurrence of a weld line or the like which is acause of decreasing in coupling strength between the core 1C and the rimportion 2C.

The worm wheel 10C includes the second annular recess 13A having thethird annular recess 14A as well as the first annular recess 12 formedon the core 1C, and has a fixation of the second inner circumferentialportion 23C of the rim portion 2C to the second annular recess 13A, inaddition to a fixation of the first inner circumferential portion 22 ofthe rim portion 2C to the first annular recess 12. Thus, couplingstrength between the core 1C and the rim portion 2C is higher than thatof a worm wheel 100 in FIG. 27.

Also, because the outer circumferential wall surface of the secondannular recess 13A is formed in a shape having the third right-angledannular recess 14A on the tapered surface, the worm wheel 10C can bemade to have a further increased coupling strength between the core 1Cand the rim portion 2C, as compared to a configuration having a shapeconsisting of only a tapered surface.

The worm wheel 10C is used in a speed reducer for a worm gear mechanismof an electric power steering apparatus.

FIG. 19 shows the electric power steering apparatus having the speedreducer, into which the worm wheel 10C is incorporated. FIG. 20 is aview explaining the speed reducer worm gear mechanism in FIG. 19.

In this example, an output shaft 51 and a steering shaft 52 in asteering mechanism for the electric power steering apparatus are coupledto each other by a torsion bar 53. A torque sensor 55 is installed on aninner surface of a housing 54 rotatably supporting the output shaft 51.The torque sensor 55 measures a torque transmitted between the steeringshaft 52 and the output shaft 51.

As shown in FIG. 20, a worm 58 is coupled on an output shaft 57 of anelectric motor 56. The gear 21 of the worm wheel 10C is engaged with theworm 58.

According to the electric power steering apparatus, an electric currentis supplied to the electric motor 56 based on a torque value measured bythe torque sensor 55, and thus an appropriate assistant torque isapplied to the output shaft 51 through the speed reducer including theworm 57 and the worm wheel 10C.

FIG. 21 is a sectional view showing a worm wheel according to a fifthembodiment, and FIG. 22 is an enlarged view showing a part thereof.

As shown in FIGS. 21 and 22, the worm wheel 10D of the fifth embodimenthas a core 1D made of metal and a substantially annular rim portion 2Dcovering an outer circumference 15 of the core 1D.

The core 1D is formed in a substantially circular disk shape. The core1D has a center hole 11, into which a shaft is fitted, one axial endsurface having a first annular recess 12 formed thereon, the other axialend surface having a second annular recess 13B formed thereon, and theouter circumference 15 having a spline 15 a formed thereon. A part ofthe core 1D, which is located more radially inward than the firstannular recess 12, becomes a boss portion 11 a having the center hole11.

As shown in FIG. 22, the other axial end surface of the core 1D has endsurface portions 13Ba, 13Bb, between which the second annular recess 13Bis located as viewed in a radial direction thereof. The end surfaceportion 13Ba, 13Bb are a flat surface and are arranged on the same planeas shown by a one-dot chain line F. The second annular recess 13B has abottom surface 13Bd, and an inner circumferential wall surface 13Beextending from the bottom surface 13Bd toward the end surface portion13Bb in a tapered shape to form an obtuse angle relative to the bottomsurface 13Bd.

An outer circumferential wall surface of the second annular recess 13Bhas a tapered surface 13Bc extending from the bottom surface 13Bd towardthe end surface portion 13Ba to form an obtuse angle relative to thebottom surface 13Ad, and a third annular recess 14B formed radiallyoutside the tapered surface 13Bc. A cross-sectional shape of the thirdannular recess 14B is a right-angled triangle having, as two sides ofthe triangle, a surface (surface along a line L1) parallel to the bottomsurface 13Bd of the second annular recess 13B and a surface (surfacealong a line L2) perpendicular to the bottom surface 13Bd. The surfaceof the third annular recess 14B, which is perpendicular to the bottomsurface 13Bd of the second annular recess 13B, extends straight to reachthe end surface portion 13Ba on the other axial end surface of the core1D. The surface (surface along the line L2) of the third annular recess14B perpendicular to the bottom surface 13Bd of the second annularrecess 13B is configured as a cylindrical surface. An outercircumferential wall surface 12 a of the first annular recess 12 isconfigured as a cylindrical surface having a diameter smaller than thatof the surface of the third annular recess 14B perpendicular to thebottom surface 13Bd of the second annular recess 13B.

The rim portion 2D is integrally formed with the core 1D by injectionmolding of synthetic resin. A gear 21 is formed on an outercircumferential portion of the rim portion 2 d. The rim portion 2D has afirst inner circumferential portion 22 fixed to the first annular recess12 of the core 1D and a second inner circumferential portion 23B fixedto the second annular recess 13B.

As shown in FIG. 22, the first inner circumferential portion 22 extendsfrom one axial end surface of the rim portion 2D to a radially outerregion of the first annular recess 12 and is fixed to the outercircumferential wall surface 12 a of the first annular recess 12 and aradially outer portion 12 b of a bottom surface thereof. The secondinner circumferential portion 23B extends from the other axial endsurface of the rim portion 2D to a radially outer region of the secondannular recess 13B and is fixed to the outer circumferential wallsurface (tapered surface 13Bc and third annular recess 14B) of thesecond annular recess 13B and a radially outer portion of the bottomsurface 13Bd thereof. An inner circumferential surface of the secondinner circumferential portion 23B extends along a line L3 to be parallelto the tapered surface 13Bc of the second annular recess 13B.

The rim portion 2D has a protrusion engaged with a valley of the spline15 a of the core 1D. By such an engagement of the protrusion of the rimportion 2D with the valley of the spline 15 a of the core 1D, the rimportion 2D and the core 1D are coupled to each other to be integrallyrotated and thus to allow a torque to be transmitted therebetween.

The worm wheel 10D is manufactured by the same method as those of thefourth embodiment, except that a shape of the core used is differenttherefrom. FIG. 23 is a view corresponding to FIG. 17 in the fourthembodiment, and FIG. 24 is a view corresponding to FIG. 18 in the fourthembodiment.

In the fifth embodiment, a relationship of the depth D of the secondannular recess 13B and the gate thickness T satisfies D≦T/2, the taperedsurface 3Bc is formed radially inward of the third annular recess 14B,and the end surface portions 13Ba, 13Bb, between which the secondannular recess 13B is disposed, are arranged on the same plane F.Therefore, a flow of the synthetic resin is hardly disturbed duringinjection molding of the synthetic resin. Thus, the synthetic resin isclearly expanded over the whole of the cavity (up to the first annularrecess 12, which is a terminal part of the flow), thereby preventingoccurrence of a weld line or the like which is a cause of decreasing incoupling strength between the core 1A and the rim portion 2D.

The worm wheel 10D includes the second annular recess 13B having thethird annular recess 14B as well as the first annular recess 12 formedon the core 1D and has a fixation of the second inner circumferentialportion 23B of the rim portion 2C to the second annular recess 13B, inaddition to a fixation of the first inner circumferential portion 22 ofthe rim portion 2C to the first annular recess 12, and thus, couplingstrength between the core 1D and the rim portion 2D is higher than thatof a worm wheel 100 in FIG. 27.

Also, because the outer circumferential wall surface of the secondannular recess 13B is formed in a shape having the third right-angledannular recess 14B on an outer diameter portion of the tapered surfaceBc, the worm wheel 10C can be made to have a further increased couplingstrength between the core 1D and the rim portion 2D, as compared to aconfiguration having a shape consisting of only a tapered surface.

The worm wheel 10D is used in a speed reducer for a worm gear mechanismof an electric power steering apparatus.

FIG. 25 shows the electric power steering apparatus having the speedreducer, into which the worm wheel 10D is incorporated. FIG. 26 is aview explaining the worm gear mechanism forming the speed reducer inFIG. 25. FIG. 25 is a view corresponding to FIG. 19 in the fourthembodiment, and FIG. 24 is a view corresponding to FIG. 20 in the fourthembodiment.

The present invention is based on Japanese Patent Application No.2013-034912 filed on Feb. 25, 2013, Japanese Patent Application No.2013-034913 filed on Feb. 25, 2013, and Japanese Patent Application No.2013-045857 filed on Mar. 7, 2013, the entire contents of which areincorporated herein by reference.

INDUSTRIAL APPLICABILITY

The present invention can be applied to a worm wheel forming a speedreducer for an electric power steering apparatus, in which a power of anelectric motor is transmitted to a steering mechanism to assiststeering.

EXPLANATION OF REFERENCE SIGNS

-   -   1, 1A, 1B, 1C, 1D Core    -   11 Center Hole    -   12 First Annular Recess    -   12 a Outer Circumferential Wall Surface of First Annular Recess    -   12 b Radially Outer Portion of A Bottom Surface of First Annular        Recess    -   13, 13A, 13B Second Annular Recess    -   13 a, 13 b, 13Aa, 13Ba, 13Ab, 13Bb End Surface Portions between        which Second Annular Recess is Provided    -   13 c Outer Circumferential Wall Surface of Second Annular Recess    -   13Ac, 13Bc Tapered Surface of Second Annular Recess    -   13 d, 13Ad, 13Bd Bottom Surface of Second Annular Recess    -   13 e, 13Ae, 13Be Inner Circumferential Surface of Second Annular        Recess    -   13Af Outer Tapered Surface    -   2, 2A, 2B, 2C, 2D Rim Portion    -   21 Gear    -   22 First Inner Circumferential Portion    -   23, 23A, 23B Second Inner Circumferential Portion    -   34 a Sprue    -   34 b Recessed Portion Forming Disk Gate    -   10, 10A, 10B, 10C, 10D Worm Wheel    -   51 Output Shaft of Electric Power Steering Apparatus (Steering        Mechanism)    -   52 Steering Shaft (Steering Mechanism)    -   56 Electric Motor    -   D Depth of Second Annular Recess    -   T Gate Thickness

The invention claimed is:
 1. A worm wheel comprising: a disk-shaped coremade of metal; and an annular rim portion made of synthetic resin andcovering an outer circumferential portion of the core; wherein a gear isformed on an outer circumferential portion of the rim portion, whereinthe rim portion is integrally formed with the core by synthetic resininjection molding, wherein the core comprises a center hole into which ashaft is fitted extending in an axial direction, a first axial endsurface formed with a first annular recess, and a second axial endsurface formed with a second annular recess, wherein the first annularrecess is formed at a radially inner side with respect to the outercircumferential portion of the core and is recessed toward an axiallyinner side with respect to a first axial end surface of the outercircumferential portion of the core, and the second annular recess isformed at a radially inner side with respect to the outercircumferential portion of the core and is recessed toward an axiallyinner side with respect to the a second axial end surface of the outercircumferential portion of the core, wherein the rim portion comprises afirst inner circumferential portion extending from a first axial endsurface of the rim portion to the radially outer region of the firstannular recess and fixed to the radially outer region of the firstannular recess, and a second inner circumferential portion extendingfrom a second axial end surface of the rim portion to a radially outerregion of the second annular recess and fixed to the radially outerregion of the second annular recess, wherein the rim portion isinjection-molded in a state in which the core is arranged in a mold suchthat the second annular recess faces a gate and such that the axialdirection of a sprue and the axial direction of the core are alignedwith each other, wherein an outer circumferential wall surface of thesecond annular recess extends from a bottom surface of the secondannular recess so as to be perpendicular to the bottom surface, andwherein a depth of the second annular recess is at least 0.1 mm but notdeeper than half of an axial distance between the second axial endsurface of the core and the second axial end surface of the rim portion.2. The worm wheel according to claim 1, wherein the depth of the secondannular recess is between 0.5 mm and 3.0 mm.
 3. The worm wheel accordingto claim 1, wherein the second axial end surface of the core comprisesend surface portions between which, in a radial direction, the secondannular recess is disposed, and wherein each of the end surface portionsis a flat surface.
 4. The worm wheel according to claim 3, wherein theflat surfaces forming the respective end surface portions are arrangedon a same plane.
 5. The worm wheel according to claim 1, wherein thegate is a disk gate and the rim portion is injection molded using thedisk gate.
 6. An electric power steering apparatus comprising: a speedreducer comprising the worm wheel according to claim 1; an electricmotor; and a steering mechanism, wherein the electric motor assistssteering by transmitting power of the electric motor to the steeringmechanism through the speed reducer.
 7. The worm wheel according toclaim 1, wherein at least a portion of the first annular recess isaligned with at least a portion of the second annular recess in theaxial direction.